Electrolytic capacitor and method for manufacturing same

ABSTRACT

An electrolytic capacitor includes a capacitor element, a solid electrolyte layer, an electrolyte solution. The capacitor element has an anode foil with a dielectric layer, and a cathode foil. The solid electrolyte layer is provided between the anode foil and the cathode foil. And the capacitor element is impregnated with the electrolyte solution. The cathode foil includes a covering layer that contains at least one metal selected from titanium and nickel or a compound of the at least one metal. And the solid electrolyte layer contains a conductive polymer, a polymer dopant, and a base component.

CROSS-REFERENCE OF RELATED APPLICATIONS

This application is a Continuation of U.S. patent application Ser. No.16/681,397, filed on Nov. 12, 2019, which is a Continuation of U.S.patent application Ser. No. 15/963,233, filed on Apr. 26, 2018, now U.S.Pat. No. 10,593,486, which is a Continuation of International PatentApplication No. PCT/JP2016/004906, filed on Nov. 17, 2016, which in turnclaims the benefit of Japanese Application No. 2015-231293, filed onNov. 27, 2015, the entire disclosures of which Applications areincorporated by reference herein.

TECHNICAL FIELD

The present disclosure relates to an electrolytic capacitor including asolid electrolyte layer and an electrolyte solution, and a method formanufacturing the electrolytic capacitor.

BACKGROUND

As a capacitor having a small size, a large capacitance, and low ESR(Equivalent Series Resistance), one of promising candidates is anelectrolytic capacitor including an anode foil on which a dielectriclayer is formed, a solid electrolyte layer formed so as to cover atleast a part of the dielectric layer, and an electrolyte solution. Forexample, Unexamined Japanese Patent Publication No. 2009-111174discloses an electrolytic capacitor obtained by impregnating a solidelectrolyte layer with a solvent containing, for example,γ-butyrolactone or sulfolane.

Further, for example, Unexamined Japanese Patent Publication No.2004-128048 discloses an electrolytic capacitor including an anode foil,a solid electrolyte layer, and a cathode foil on which a coating filmmade of a metal nitride or a metal is formed.

SUMMARY

An electrolytic capacitor according to the present disclosure includes acapacitor element, a solid electrolyte layer, and an electrolytesolution. The capacitor element has an anode foil with a dielectriclayer, and a cathode foil. The solid electrolyte layer is providedbetween the anode foil and the cathode foil. And the capacitor elementis impregnated with the electrolyte solution. The cathode foil includesa covering layer that contains at least one metal selected from titaniumand nickel or a compound of the at least one metal. And the solidelectrolyte layer contains a conductive polymer, a polymer dopant, and abase component.

A method for manufacturing an electrolytic capacitor according to thepresent disclosure includes the steps of; forming a capacitor elementincluding an anode foil on which a dielectric layer is formed, and acathode foil; forming a solid electrolyte layer between the anode foiland the cathode foil; and impregnating with an electrolyte solution thecapacitor element in which a solid electrolyte layer has been formed. Acovering layer that contains at least one metal selected from titaniumand nickel or a compound including the at least one metal is formed onthe cathode foil. And the solid electrolyte layer is formed byimpregnating the capacitor element with a dispersion containing theconductive polymer, a polymer dopant, a base component, and a solventand then removing at least a part of the solvent.

According to the present disclosure, there can be provided anelectrolytic capacitor having a high electrostatic capacity and low ESR.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a schematic sectional view illustrating an electrolyticcapacitor according to one exemplary embodiment of the presentdisclosure.

FIG. 2 is a schematic view illustrating a configuration of a capacitorelement according to the exemplary embodiment.

DESCRIPTION OF EMBODIMENT

In the conventional electrolytic capacitor including a solid electrolytelayer and an electrolyte solution, there is a problem that neither asufficiently high electrostatic capacity nor low ESR might be obtain byforming the solid electrolyte layer with use of a dispersion containinga conductive polymer even when a titanium coating film is formed on acathode foil.

In order to solve the problem, the present disclosure provides anelectrolytic capacitor having a high electrostatic capacity and low ESR.

Hereinafter, the present disclosure is more specifically described withreference to an exemplary embodiment. The exemplary embodiment below,however, is not to limit the present disclosure.

FIG. 1 is a schematic sectional view illustrating an electrolyticcapacitor according to the present exemplary embodiment, and FIG. 2 is aschematic view obtained by developing a part of a capacitor element ofthe electrolytic capacitor.

The electrolytic capacitor includes, for example, capacitor element 10,bottomed case 11 that houses capacitor element 10, sealing member 12that seals an opening of bottomed case 11, base plate 13 that coverssealing member 12, lead wires 14A, 14B that are lead out from sealingmember 12 and penetrate base plate 13, lead tabs 15A, 15B that connectthe lead wires to electrodes of capacitor element 10, respectively, andan electrolyte solution (not shown). Bottomed case 11 is, at a part nearan opening end, processed inward by drawing, and is, at the opening end,curled to swage sealing member 12.

Capacitor element 10 includes anode foil 21 connected to lead tab 15A,cathode foil 22 connected to lead tab 15B, and separator 23.

Anode foil 21 and cathode foil 22 are wound with separator 23 interposedbetween the anode foil and the cathode foil. An outermost periphery ofcapacitor element 10 is fixed with fastening tape 24. FIG. 2 showspartially developed capacitor element 10 before the outermost peripheryof the capacitor element is fixed.

Anode foil 21 includes a metal foil whose surface is roughened so as tohave projections and recesses, and a dielectric layer is formed on themetal foil having the projections and recesses. A conductive polymer isattached to at least a part of a surface of the dielectric layer to forma solid electrolyte layer. The solid electrolyte layer may cover atleast a part of a surface of cathode foil 22 and/or at least a part of asurface of separator 23. Capacitor element 10 in which the solidelectrolyte layer has been formed is housed in bottomed case 11 togetherwith the electrolyte solution.

An electrolytic capacitor according to the present disclosure includesan anode foil with a dielectric layer; a cathode foil; a solidelectrolyte layer in contact with the dielectric layer; and anelectrolyte solution. The cathode foil includes a covering layercontaining at least one metal selected from titanium and nickel or acompound of the at least one metal. The solid electrolyte layer containsa conductive polymer, a polymer dopant, and a base component.

<<Method for Manufacturing Electrolytic Capacitor>>

Hereinafter, described are steps of one exemplary method formanufacturing the electrolytic capacitor according to the presentexemplary embodiment.

(i) Step of Preparing Anode Foil 21 with Dielectric Layer

First, a metal foil as a raw material for anode foil 21 is prepared. Atype of the metal is not particularly limited, but it is preferred touse a valve metal such as aluminum, tantalum, or niobium, or an alloycontaining a valve metal, from the viewpoint of facilitating formationof a dielectric layer.

Next, a surface of the metal foil is roughened. By the roughening, aplurality of projections and recesses are formed on the surface of themetal foil. The roughening is preferably performed by etching the metalfoil. The etching may be performed by, for example, a direct-currentelectrolytic method or an alternating-current electrolytic method.

Next, a dielectric layer is formed on the roughened surface of the metalfoil. A method for forming the dielectric layer is not particularlylimited, and the dielectric layer can be formed by subjecting the metalfoil to an anodizing treatment. The anodizing treatment is performed by,for example, immersing the metal foil in an anodizing solution such asan ammonium adipate solution, followed by a heat treatment. Theanodizing treatment may also be performed by applying a voltage to themetal foil that has been immersed in the anodizing solution.

Normally, a large foil of, for example, a valve metal (metal foil) issubjected to the roughening treatment and the anodizing treatment fromthe viewpoint of mass productivity. In this case, the treated foil iscut into a desired size to prepare anode foil 21.

(ii) Step of Preparing Cathode Foil 22

Next, cathode foil 22 including a metal foil and a covering layer formedon a surface of the metal foil is prepared. Cathode foil 22 includingthe covering layer can increase an electrostatic capacity of acapacitor. A type of the metal that constitutes the metal foil is notparticularly limited, but it is preferred to use a valve metal such asaluminum, tantalum, or niobium, or an alloy containing a valve metal.The surface of the metal foil may be roughened as necessary beforeformation of the covering layer.

The covering layer contains at least one metal selected from titaniumand nickel or a compound of the at least one metal. As the metalcompound, there can be used a nitride and a carbide. The covering layermay also include a layer containing carbon on a surface of the coveringlayer. On the other hand, a cathode foil obtained by fixing carbonparticles as aluminum carbide on a surface of an aluminum foil is notpreferred because aluminum carbide is hydrolyzed by a little amount ofmoisture contained in an electrolyte solution described later. As amethod for forming the covering layer, there can be used gas phasemethods such as a vacuum deposition method, a chemical vapor depositionmethod, a sputtering method, and an ion plating method.

(iii) Production of Capacitor Element 10

Next, capacitor element 10 is produced with use of anode foil 21 andcathode foil 22. First, anode foil 21 and cathode foil 22 are wound withseparator 23 interposed between the anode foil and the cathode foil. Atthis time, the winding can be conducted while lead tabs 15A, 15B arerolled in the anode foil, the cathode foil, and the separator, to causelead tabs 15A, 15B to stand up from capacitor element 10 as illustratedin FIG. 2.

As a material for separator 23, a nonwoven fabric can be used thatincludes, as a main component, for example, cellulose, polyethyleneterephthalate, polyacrylonitrile, vinylon, or an aramid fiber.

A material for lead tabs 15A, 15B is not particularly limited as long asthe material is a conductive material. A material for lead wires 14A,14B connected to lead tabs 15A, 15B, respectively, is not alsoparticularly limited as long as the material is a conductive material.

Next, fastening tape 24 is disposed on an outer surface of cathode foil22 positioned at an outermost layer of wound anode foil 21, cathode foil22, and separator 23, to fix an end of cathode foil 22 with fasteningtape 24. When anode foil 21 is prepared by cutting a large metal foil,the wound body may further be subjected to an anodizing treatment inorder to provide a dielectric layer on a cutting surface of anode foil21.

(iv) Step of Forming Solid Electrolyte Layer

Next, the dielectric layer is impregnated with a polymer dispersion toform a film covering at least a part of the dielectric layer. Thepolymer dispersion contains a solvent, a conductive polymer, a polymerdopant, and a base component. The polymer dispersion may be a solutionobtained by dissolving the conductive polymer in the solvent, or adispersion liquid obtained by dispersing particles of the conductivepolymer in the solvent. Next, the solvent is volatilized from the formedfilm by drying, and then a dense solid electrolyte layer covering atleast a part of the dielectric layer is formed. In the polymerdispersion, the conductive polymer is uniformly distributed in thesolvent to easily form a uniform solid electrolyte layer. Thus,capacitor element 10 can be obtained.

As the base component, it is preferred to use, for example, ammonia, aprimary to tertiary amine, a quaternary ammonium, and a quaternizedamidinium. As the primary to tertiary amine, there can be used, forexample, methylamine, dimethylamine, trimethylamine, ethylamine,diethylamine, triethylamine, ethylenediamine, N,N-diisopropylethylamine,tetramethylethylenediamine, and hexamethylenediamine. As the quaternaryammonium, there can be used, for example, tetramethylammonium,triethylmethylammonium, and tetraethylammonium. As the quaternizedamidinium, there can be used, for example, ethyldimethylimidazoliniumand tetramethylimidazolinium.

A polymer dispersion containing no base component has lower wettabilityto a cathode foil that includes a covering layer containing, forexample, titanium, nickel, or carbon than to a cathode foil thatincludes an anodizing coating film. Therefore, the polymer dispersioncontaining no base component gives insufficient adhesiveness between aresultant solid electrolyte layer and the cathode foil and/orinsufficient covering properties, so that the electrostatic capacity andthe ESR of a capacitor might be deteriorated. On the other hand, apolymer dispersion containing a base component has high wettability to acathode foil including the covering layer. Therefore, the polymerdispersion containing a base component gives good adhesiveness between aresultant solid electrolyte layer and the cathode foil, and goodcovering properties, so that the electrostatic capacity and the ESR of acapacitor can be improved. The polymer dispersion can be obtained by,for example, a method for dispersing the conductive polymer in a liquidcomponent or a method for polymerizing a precursor monomer in a liquidcomponent and generating particles of the conductive polymer.

The conductive polymer is preferably, for example, polypyrrole,polythiophene, or polyaniline. These conductive polymers may be usedalone, or two or more of the conductive polymers may be used incombination, or a copolymer of two or more monomers may be used. Aresultant solid electrolyte layer containing such a conductive polymercan be expected to further improve withstand voltage characteristics.

In the present specification, polypyrrole, polythiophene, polyaniline,and the like mean polymers having, as a basic skeleton, polypyrrole,polythiophene, polyaniline, and the like, respectively. Therefore,polypyrrole, polythiophene, polyaniline, and the like can also includederivatives of polypyrrole, polythiophene, polyaniline, and the like,respectively. For example, polythiophene includespoly(3,4-ethylenedioxythiophene) (PEDOT) and the like.

Examples of the polymer dopant include polyanions of polyvinylsulfonicacid, polystyrenesulfonic acid, polyallylsulfonic acid,polyacrylsulfonic acid, polymethacrylsulfonic acid,poly(2-acrylamido-2-methylpropanesulfonic acid), polyisoprenesulfonicacid, and polyacrylic acid. These polymer dopants may be used alone, ortwo or more of the dopants may be used in combination. These polymerdopants may be a homopolymer or a copolymer of two or more monomers.Especially, polystyrenesulfonic acid (PSS) is preferred.

A weight average molecular weight of the polymer dopant is notparticularly limited but preferably ranges, for example, from 1000 to500000, inclusive, in terms of facilitating formation of a homogeneoussolid electrolyte layer.

The solvent may be water, a mixture of water and a nonaqueous solvent,or a nonaqueous solvent. The nonaqueous solvent is not particularlylimited, and a protic solvent and an aprotic solvent can be used, forexample. Examples of the protic solvent include alcohols such asmethanol, ethanol, propanol, butanol, ethylene glycol, propylene glycol,and a polyalkylene glycol, formaldehyde, and ethers such as 1,4-dioxane.Examples of the aprotic solvent include amides such asN-methylacetamide, N,N-dimethylformamide, and N-methyl-2-pyrrolidone,esters such as methyl acetate, and ketones such as methyl ethyl ketone.

A concentration of the conductive polymer contained in the polymerdispersion preferably ranges from 0.5% by mass to 10% by mass,inclusive. An average particle diameter D50 of the conductive polymerpreferably ranges, for example, from 0.01 μm to 0.5 μm, inclusive. Here,the average particle diameter D50 is a median diameter in a volumeparticle size distribution obtained by a particle size distributionmeasuring apparatus according to dynamic light scattering. The polymerdispersion having such a concentration is suitable for forming a solidelectrolyte layer having an appropriate thickness and is easilyimpregnated into the dielectric layer.

A concentration of the base component contained in the polymerdispersion ranges preferably from 0.001 mol/kg to 0.04 mol/kg,inclusive, particularly preferably from 0.003 mol/kg to 0.03 mol/kg,inclusive.

As a method for applying the polymer dispersion to a surface of thedielectric layer, for example, a method for immersing the wound body inthe polymer dispersion housed in a container is simple and preferred. Animmersion period depends on a size of the wound body and ranges, forexample, from 1 second to 5 hours, inclusive, preferably from 1 minuteto 30 minutes, inclusive. In addition, impregnation is preferablyperformed under a reduced pressure, in an atmosphere ranging, forexample, from 10 kPa to 100 kPa, inclusive, preferably from 40 kPa to100 kPa, inclusive. Further, ultrasonic vibration may be applied to thewound body or the polymer dispersion while the wound body is immersed inthe polymer dispersion. The drying after picking the wound body up fromthe polymer dispersion is preferably performed at a temperature rangingfrom 50° C. to 300° C., inclusive, more preferably from 100° C. to 200°C., inclusive, for example.

The step of applying the polymer dispersion to the surface of thedielectric layer and the step of drying capacitor element 10 may berepeated two or more times. These steps can be performed a plurality oftimes to increase coverage of the solid electrolyte layer on thedielectric layer. In the formation, the solid electrolyte layer may beformed on not only the surface of the dielectric layer but also surfacesof cathode foil 22 and separator 23.

As described above, the solid electrolyte layer is formed between anodefoil 21 and cathode foil 22. The solid electrolyte layer formed on thesurface of the dielectric layer actually functions as a cathodematerial.

(v) Step of Impregnating Capacitor Element 10 with Electrolyte Solution

Next, capacitor element 10 is impregnated with an electrolyte solution.A method for impregnating capacitor element 10 with the electrolytesolution is not particularly limited. For example, a method forimmersing capacitor element 10 in the electrolyte solution housed in acontainer is simple and preferred. An immersion period depends on a sizeof capacitor element 10 and ranges, for example, from 1 second to 5minutes, inclusive. Impregnation is preferably performed under a reducedpressure, in an atmosphere ranging, for example, from 10 kPa to 100 kPa,inclusive, preferably from 40 kPa to 100 kPa, inclusive.

The electrolyte solution can contain, for example, a polyhydric alcohol,a sulfone compound, a lactone compound, a carbonate compound, and amonohydric alcohol. These alcohols and compounds may be used alone or incombination of a plurality of alcohols and compounds.

The polyhydric alcohol desirably includes at least one of ethyleneglycol, diethylene glycol, triethylene glycol, propylene glycol, butanediol, a polyalkylene glycol, or glycerol, for example. As thepolyalkylene glycol, it is preferred to use polyethylene glycol havingan average molecular weight ranging from 200 to 1000, inclusive, orpolypropylene glycol having an average molecular weight ranging from 200to 5000, inclusive.

As the lactone compound, there can be used, for example, γ-butyrolactoneand γ-valerolactone. As to the carbonate compound, the electrolytesolution can contain, as a solvent, dimethyl carbonate, diethylcarbonate, ethyl methyl carbonate, ethylene carbonate, propylenecarbonate, and fluoroethylene carbonate, for example. Particularly, itis desired to use ethylene glycol, a polyalkylene glycol,γ-butyrolactone, and sulfolane.

The electrolyte solution may also contain a solute. As the solute, therecan be used, for example, an acid component, a base component, a salt ofan acid component and a base component, a nitro compound, and a phenolcompound.

As the acid compound, there can be used an organic acid, an inorganicacid, and a composite compound of an organic acid and an inorganic acid.As the organic acid, there can be used, for example, phthalic acid,isophthalic acid, terephthalic acid, maleic acid, adipic acid, benzoicacid, and carboxylic acids such as 1,6-decanedicarboxylic acid,1,7-octanedicarboxylic acid, and azelaic acid. As the inorganic acid,there can be used, for example, boric acid, phosphoric acid, phosphorousacid, hypophosphorous acid, and a phosphate ester.

As the composite compound of an organic acid and an inorganic acid,there can be used, for example, borodisalicylic acid, borodioxalic acid,and borodiglycolic acid.

As the base component, there can be used, for example, a primary totertiary amine, a quaternary ammonium, and a quaternized amidinium. Asthe primary to tertiary amine, there can be used, for example,methylamine, dimethylamine, trimethylamine, ethylamine, diethylamine,triethylamine, ethylenediamine, N,N-diisopropylethylamine,tetramethylethylenediamine, and hexamethylenediamine. As the quaternaryammonium, there can be used, for example, tetramethylammonium,triethylmethylammonium, and tetraethylammonium. As the quaternizedamidinium, there can be used, for example, ethyldimethylimidazoliniumand tetramethylimidazolinium.

A proportion of the solute contained in the electrolyte solutiondesirably ranges from 0% by mass to 30% by mass, inclusive. When theproportion of the solute is in this range, an increase in viscosity ofthe electrolyte solution is small, and a voltage is less likely todecrease.

(vi) Step of Encapsulating Capacitor Element

Next, capacitor element 10 is encapsulated. Specifically, first,capacitor element 10 is housed in bottomed case 11 so that lead wires14A, 14B are positioned on an open upper surface of bottomed case 11. Asa material for bottomed case 11, there can be used metals such asaluminum, stainless steel, copper, iron and brass, or alloys of thesemetals.

Next, sealing member 12 formed so as to allow lead wires 14A, 14B topenetrate the sealing member is disposed above capacitor element 10 soas to encapsulate capacitor element 10 in bottomed case 11. Next,bottomed case 11 is, at a part near an opening end, processed bytransverse drawing, and is, at the opening end, curled to swage sealingmember 12. Then, base plate 13 is disposed on a curled part of thebottomed case to complete the electrolytic capacitor as illustrated inFIG. 1. Then, an aging treatment may be performed while a voltage isapplied.

Sealing member 12 is formed of an elastic material containing a rubbercomponent. As the rubber component, there can be used a butyl rubber(IIR), a nitrile rubber (NBR), an ethylene propylene rubber, an ethylenepropylene diene rubber (EPDM), a chloroprene rubber (CR), an isoprenerubber (IR), a Hypalon (trademark) rubber, a silicone rubber, and afluorine-containing rubber. Sealing member 12 may contain fillers suchas carbon black and silica.

EXAMPLES

Hereinafter, the present disclosure is described in more detail withreference to examples. The present disclosure, however, is not to beconsidered to be limited to the examples.

Example 1

In the present example, a wound electrolytic capacitor having a ratedvoltage of 35 V and a rated electrostatic capacity of 330 μF wasproduced. Hereinafter, a specific method for manufacturing theelectrolytic capacitor is described.

(Preparation of Anode Foil)

A 100-μm-thick aluminum foil was subjected to etching to roughen asurface of the aluminum foil. Then, a dielectric layer was formed on thesurface of the aluminum foil by an anodizing treatment. The anodizingtreatment was performed by immersing the aluminum foil in an ammoniumadipate solution and applying a voltage to the aluminum foil. Then, thealuminum foil was cut into a size of 6 mm (length)×120 mm (width) toprepare an anode foil.

(Preparation of Cathode Foil)

A 50-μm-thick aluminum foil was subjected to etching, and a titaniumlayer and a carbon layer were sequentially formed as a covering layer.Then, the aluminum foil was cut into a size of 6 mm (length)×120 mm(width) to prepare a cathode foil.

(Production of Capacitor Element)

An anode lead tab and a cathode lead tab were connected to the anodefoil and the cathode foil, respectively, and the anode foil and thecathode foil were wound with a separator interposed between the anodefoil and the cathode foil while the lead tabs were rolled in the anodefoil, the cathode foil, and the separator. Ends of the lead tabsprotruding from a wound body were connected to an anode lead wire and acathode lead wire, respectively. Then, the produced wound body wassubjected to an anodizing treatment again to form a dielectric layer ata cutting end of the anode foil. Next, an end of an outer surface of thewound body was fixed with a fastening tape to produce a capacitorelement.

(Preparation of Polymer Dispersion)

A mixed solution was prepared by dissolving 3,4-ethylenedioxythiopheneand polystyrenesulfonic acid (PSS, weight average molecular weight100000) in ion-exchanged water (liquid component). While the mixedsolution was stirred, iron (III) sulfate (oxidant) that had beendissolved in ion-exchanged water was added to the mixed solution tocause a polymerization reaction. After the reaction, a resultantreaction solution was dialyzed to remove unreacted monomers and anexcessive oxidant, so that a polymer dispersion was obtained thatcontained about 2% by mass of polyethylene dioxythiophene doped with PSS(PEDOT/PSS). Then, ammonia was added as a base component in an amount of0.02 mol with respect to 1 kg of the polymer dispersion.

(Formation of Solid Electrolyte Layer)

The capacitor element was immersed in the polymer dispersion housed in apredetermined container in a reduced-pressure atmosphere (40 kPa) for 5minutes, and then the capacitor element was picked up from the polymerdispersion. Next, the capacitor element that had been impregnated withthe polymer dispersion was dried in a drying furnace at 150° C. for 20minutes so as to form a solid electrolyte layer covering at least a partof the dielectric layer.

(Impregnation with Electrolyte Solution)

An electrolyte solution was prepared that contained 40% by mass ofγ-butyrolactone, 40% by mass of sulfolane, and 20% by mass ofethyldimethylamine phthalate, and the capacitor element was immersed inthe electrolyte solution for 5 minutes in a reduced-pressure atmosphere(40 kPa).

(Encapsulation of Capacitor Element)

The capacitor element that had been impregnated with the electrolytesolution was encapsulated to complete an electrolytic capacitor.Specifically, the capacitor element was housed in a bottomed case sothat lead wires were positioned on an opening side of the bottomed case.And a sealing member (an elastic material including a butyl rubber as arubber component) that was formed so as to allow the lead wires topenetrate the sealing member was disposed above the capacitor element,so as to encapsulate the capacitor element in the bottomed case. Thebottomed case was, at a part near an opening end, processed by drawingand was further curled at the opening end, and a base plate was disposedon a curled part to complete the electrolytic capacitor as illustratedin FIG. 1. Thereafter, an aging treatment was performed at 130° C. for 2hours while a rated voltage was applied.

Example 2

An electrolytic capacitor was produced in the same manner as in Example1 except that diethylamine was used as the base component, and theevaluation was performed in the same manner.

Example 3

An electrolytic capacitor was produced in the same manner as in Example1 except that diethanolamine was used as the base component, and theevaluation was performed in the same manner.

Example 4

An electrolytic capacitor was produced in the same manner as in Example1 except that dimethylaminoethanol was used as the base component, andthe evaluation was performed in the same manner.

Example 5

An electrolytic capacitor was produced in the same manner as in Example1 except that ammonia was added in an amount of 0.001 mol with respectto 1 kg of the polymer dispersion, and the evaluation was performed inthe same manner.

Example 6

An electrolytic capacitor was produced in the same manner as in Example1 except that ammonia was added in an amount of 0.003 mol with respectto 1 kg of the polymer dispersion, and the evaluation was performed inthe same manner.

Example 7

An electrolytic capacitor was produced in the same manner as in Example1 except that ammonia was added in an amount of 0.03 mol with respect to1 kg of the polymer dispersion, and the evaluation was performed in thesame manner.

Example 8

An electrolytic capacitor was produced in the same manner as in Example1 except that ammonia was added in an amount of 0.04 mol with respect to1 kg of the polymer dispersion, and the evaluation was performed in thesame manner.

Example 9

An electrolytic capacitor was produced in the same manner as in Example1 except that a titanium nitride layer was formed as the covering layerin place of the titanium layer and the carbon layer, and the evaluationwas performed in the same manner.

Example 10

An electrolytic capacitor was produced in the same manner as in Example1 except that a nickel layer was formed as the covering layer in placeof the titanium layer and the carbon layer, and the evaluation wasperformed in the same manner.

Comparative Example 1

An electrolytic capacitor was produced in the same manner as in Example1 except that a cathode foil was used that included, in place of thecovering layer, a anodizing coating film formed through anodizing at 2V, and the evaluation was performed in the same manner.

Comparative Example 2

An electrolytic capacitor was produced in the same manner as in Example1 except that no base component was added to the polymer dispersion, andthe evaluation was performed in the same manner.

[Evaluation]

An electrostatic capacity (μF) was measured for the electrolyticcapacitors. Specifically, an electrostatic capacity (μF) at a frequencyof 120 Hz was measured for the electrolytic capacitors with an LCR meterfor 4-terminal measurement. An ESR value (mΩ) was also measured for theelectrolytic capacitors. Specifically, an ESR value (mΩ) at a frequencyof 100 kHz was measured for the electrolytic capacitors with an LCRmeter for 4-terminal measurement. The electrostatic capacity and the ESRvalue were each measured for randomly selected 120 electrolyticcapacitors, and average values for the electrostatic capacity and theESR value were calculated.

TABLE 1 Electrostatic capacity (μF) ESR (mΩ) Example 1 331.55 9.1Example 2 322.79 10.1 Example 3 323.87 9.4 Example 4 324.99 10.3 Example5 328.12 15.8 Example 6 329.84 12.6 Example 7 332.01 11.9 Example 8334.89 13.1 Example 9 330.55 10.1 Example 10 321.56 10.9 Comparative251.21 13.8 Example 1 Comparative 301.88 57.8 Example 2

The present disclosure can be utilized for an electrolytic capacitorthat includes a solid electrolyte layer covering at least a part of adielectric layer, and an electrolyte solution.

What is claimed is:
 1. A method for manufacturing an electrolyticcapacitor, the method comprising: forming a capacitor element includingan anode foil and a cathode foil, the anode foil including a dielectriclayer, the cathode foil including a covering layer that contains atleast one selected from the group consisting of titanium, nickel, acompound including titanium, and a compound including nickel; forming asolid electrolyte layer provided between the anode foil and the cathodefoil; and impregnating the capacitor element with a liquid substanceafter the forming of the solid electrolyte layer, the liquid substancecontaining at least one selected from the group consisting of an acidcomponent, a nitro compound, and a phenol compound, wherein in theforming of the solid electrolyte layer, the solid electrolyte layer isformed by impregnating the capacitor element with a dispersioncontaining a conductive polymer, a polymer dopant, a base component, anda solvent and then removing at least a part of the solvent.
 2. Themethod according to claim 1, wherein the base component is at least oneselected from ammonia, a primary to tertiary amine, a quaternaryammonium, and a quaternized amidinium.
 3. The method according to claim1, wherein a concentration of the base component contained in thedispersion ranges from 0.001 mol/kg to 0.04 mol/kg, inclusive.
 4. Themethod according to claim 1, wherein a concentration of the basecomponent contained in the dispersion ranges from 0.003 mol/kg to 0.03mol/kg, inclusive.
 5. The method according to claim 1, wherein theliquid substance is an electrolyte solution.
 6. The method according toclaim 1, wherein the covering layer includes a carbon layer.